Plating, Anodizing & Surface Treatment worked example

Conversion Coating Cost at 66% first-pass yield: a worked example

This worked example runs the conversion coating cost numbers for a tougher week than the baseline: 66% first-pass yield instead of the typical 92%. Estimate the total cost of applying a chemical conversion coating to a lot of parts including chemistry, immersion handling and a flat line setup charge.

The inputs for this scenario

  • Parts Coated: 500 parts (held at the documented default)
  • Coating Cost per Part: 1.85 $/part (held at the documented default)
  • First-Pass Yield: 66 % (the input this scenario stresses; the baseline uses 92)
  • Line Setup Charge: 120 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total = parts coated x coating cost per part x first-pass yield% + line setup charge.
  • Total conversion coating cost works out to 731 $ at these inputs, and this is the headline figure for the scenario.
  • Conversion coating cost per unit works out to 1.46 $ / piece at these inputs.
  • Variable conversion coating cost works out to 611 $ at these inputs.
  • Fixed conversion coating cost adder works out to 120 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where first-pass yield sits at 92% and the headline result is 971 $, this scenario comes in 24.77% below the baseline at 731 $.
  • Use it when quoting a pretreatment step, comparing chromate against non-chrome chemistries, or building a standard cost for parts that pass through a conversion coating line before paint or bonding. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total conversion coating cost: 731 $ (headline result)
  • Conversion coating cost per unit: 1.46 $ / piece
  • Variable conversion coating cost: 611 $
  • Fixed conversion coating cost adder: 120 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Conversion Coating Cost calculator, set first-pass yield to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.